Rapid flow type high-shear mixer for strengthening solid-liquid dispersion and micro-mixing performance

Abstract

The invention discloses a rapid flow type high-shear mixer for strengthening solid-liquid dispersion and micro-mixing performance, and belongs to the technical field of chemical reaction equipment. Comprising a driving motor, a transmission rod, a rotor, a stator and a stator cover plate. The wall part of the stator is thickened and is provided with an annular hole channel which is used as a built-in distributor for conveying feed liquid to a high-shear area; the stator cover plate can be adjusted to be in a fully-open state, a semi-open state or a fully-closed state, and the liquid-liquid micro-mixing process, the solid-liquid reaction process and the solid-liquid dispersion process are optimized respectively. The shearing gap between the rotor and the stator is 1-3mm, and the coupling of the limited impinging stream and high shearing is realized by combining the multi-shape design of the annular hole channel. According to the invention, the micromixing efficiency and the depolymerization capability are obviously improved, the device is suitable for phosgenation, diazotization and other rapid reactions, the energy consumption is reduced by 35-50%, the product selectivity reaches 95% or more, and the device has the advantages of compact structure, flexible operation, wide application range and the like.

Description

Technical Field

[0001] This invention belongs to the field of chemical reaction equipment technology, specifically relating to a high-shear mixer with enhanced solid-liquid dispersion and micro-mixing performance. Background Technology

[0002] In key areas related to national economic and technological development (such as new material development, fine chemical synthesis, and pharmaceutical manufacturing), there are generally chemical reaction systems with rapid competitive characteristics, such as phosgenation, diazotization, and their accompanying rearrangement processes. These reactions are characterized by millisecond-level kinetic competition between the main and side reactions, and their reaction progress is highly dependent on the precise matching between molecular-scale mixing efficiency (i.e., micro-mixing) and reaction kinetics.

[0003] Traditional stirred tank reactors, constrained by macroscopic mixing mechanisms, struggle to achieve ideal microscopic mixing, leading to low product selectivity and insufficient yield of active ingredients. This mixing deficiency not only results in low feed utilization (approximately 20%–30% material loss) but also significant energy waste (stirring energy consumption increases by over 40%) and increased emissions of waste gas, wastewater, and solid waste (byproduct generation can reach 15%–25% of the main product). By developing novel structured reactors with micrometer-level mixing characteristics (such as microchannel reactors and high-shear mixers), microscopic mixing time can be shortened to 10... -4 -10 -3 The process intensification technology, operating on the order of seconds, achieves a near-order match between the mixing characteristic time and the chemical characteristic time of rapid reactions, thereby enabling effective control of the reaction pathway. This process intensification technology can increase the selectivity of target products to over 95% while reducing energy consumption by 35% to 50%, making it a core technological path for driving the transformation and upgrading of the fine chemical industry towards high efficiency and green practices.

[0004] Although high-shear reactors (HSRs) utilize the interaction between a high-speed rotating rotor (operating linear velocity of 10-50 m / s) and the stator to generate powerful fluid turbulence and shear effects, resulting in superior micro-mixing and fragmentation capabilities compared to stirred tanks, they still have shortcomings. Traditional HSRs have a simple stator structure, leading to uneven feed delivery and distribution, making it difficult to accurately guide the feed into high-energy-dissipation regions. Inadequate stator-rotor gap design results in insufficient shear force or easy wear in some parts of the equipment. Furthermore, they lack flexible operating condition adjustment mechanisms, making them unsuitable for simultaneous adaptation to various scenarios such as liquid-liquid micro-mixing, solid-liquid dispersion, and reaction. When handling non-Newtonian fluids, they are prone to material agglomeration and localized overload, failing to meet the demands of modern industry for high-precision, highly adaptable mixing equipment. Therefore, developing novel high-shear mixers that enhance solid-liquid dispersion and micro-mixing performance and are adaptable to multiple scenarios is crucial for promoting efficient and green transformation and upgrading in fields such as fine chemicals. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to address the shortcomings of the prior art by providing a fast-flow high-shear mixer that enhances solid-liquid dispersion and micro-mixing performance. This invention addresses the technical problems of insufficient micro-mixing efficiency of traditional reactors, making them difficult to adapt to rapid competitive reactions such as phosgenation; difficulties in mixing non-Newtonian fluids and dispersing solid materials; poor adaptability to operating conditions, limiting the scope of application; and structural defects that limit stability and service life. This invention aims to improve the demand for reactors with good micro-mixing performance in modern industry.

[0006] The present invention adopts the following technical solution: A high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties includes a drive motor, which is connected to a rotor via a transmission rod to drive the rotor to rotate at high speed. The rotor is fitted with a stator, and a shear gap is formed between the stator and the rotor to generate a strong shearing effect; The upper part of the stator is adjustablely equipped with a stator cover plate, which is used to control the material suction method; The stator wall is thickened and has an annular channel inside it. The annular channel is used to transport the liquid material, so that the liquid material is mixed in the high energy dissipation area between the stator and the rotor.

[0007] Preferably, the stator cover is configured to be fully open, partially open, or fully closed: When fully open, it is suitable for liquid-liquid micro-mixing and enhances runoff; When partially open, it is suitable for solid-liquid reactions, accommodating both axial and radial flow. When fully closed, it is suitable for solid-liquid dispersion and enhances axial suction.

[0008] Preferably, the annular channel is formed by 3D printing technology, and its cross-sectional shape is one or more combinations of circles, squares, triangles, rhombuses or corrugations.

[0009] Preferably, the annular channel has a channel gap of 1-5 mm, which is one of a uniform channel, a gradually narrowing channel, or a gradually expanding channel.

[0010] Preferably, the shear gap between the rotor and the stator is 1~3mm.

[0011] Preferably, the connection between the transmission rod and the stator is sealed with polyethylene material.

[0012] Preferably, the rotor adopts a blade-type or toothed structure design, and its surface is electrochemically treated.

[0013] Preferably, the stator cover is made of stainless steel and has a frosted surface.

[0014] Preferably, the mixer is suitable for phosgenation, diazotization, rearrangement or precipitation reactions, with a reaction temperature of -30 to 80°C and a reaction pressure of 0.1 to 5 MPa.

[0015] Preferably, the stator and rotor are made of at least one of stainless steel, nickel-based alloy, ceramic material, silicon carbide, or polymer.

[0016] Compared with the prior art, the present invention has at least the following beneficial effects: A high-shear mixer with enhanced solid-liquid dispersion and micro-mixing performance utilizes a high-speed rotor driven by a motor to create a micron-level shear gap between the stator and rotor, generating extremely strong turbulence and shear force. Thickened stator walls and annular channels form an internal distributor, allowing the liquid to be directly delivered to the high-energy-dissipation region for molecular-level mixing. The stator cover can be adjusted to fully open, half-open, or fully closed to enhance radial flow (liquid-liquid mixing), axial and radial flow synergy (solid-liquid reaction), or axial suction (solid-liquid dispersion), respectively, adapting to different process requirements. This design solves the problems of low micro-mixing efficiency and easy agglomeration of solid particles in traditional mixers for non-Newtonian fluids. The annular channels, combined with the impingement flow principle, improve mixing uniformity; the adjustable cover enables multi-purpose use, reducing equipment investment; the high-shear design shortens mixing time to the millisecond level, increases reaction selectivity to over 95%, and reduces energy consumption by 35%–50%. This structure is particularly suitable for fine chemical processes such as nanomaterial dispersion and high-viscosity fluid processing, possessing significant industrial value.

[0017] Furthermore, in the fully open state, with the cover plate removed, the material is mainly drawn in from the side of the stator, forming a strong radial flow that promotes rapid micro-mixing of the liquid-liquid system. In the half-open state, the cover plate partially covers the surface, balancing axial suction and radial shear to prevent solid sedimentation, making it suitable for solid-liquid reactions. In the fully closed state, the cover plate completely seals the surface, enhancing the axial suction at the bottom and resuspending the precipitated solids for uniform dispersion. Simple mechanical adjustments allow it to adapt to various mixing scenarios without requiring equipment replacement, significantly improving operational flexibility and production efficiency. Specifically designed for non-Newtonian fluids and nanoparticle systems, it solves the problems of clogging and uneven mixing inherent in traditional equipment, reducing the time and cost of process adjustments.

[0018] Furthermore, 3D printing technology enables the precise molding of complex flow channel structures. Different cross-sectional shapes affect the fluid flow state: circular channels have low resistance and are suitable for high flow rates; polygonal channels enhance turbulence; corrugated channels promote vortex generation and increase collision frequency; 3D printing ensures the accuracy and consistency of channel processing, avoiding burrs and deviations in traditional processing; multi-shape design allows for optimization of the flow field according to material characteristics, further improving mixing efficiency and energy consumption ratio, especially suitable for high viscosity or particulate systems.

[0019] Furthermore, uniform channels ensure a stable flow field; tapered channels accelerate the fluid and increase kinetic energy; and expanding channels decelerate and pressurize, promoting collisions. A size of 1-5 mm balances flow resistance and shear strength, preventing clogging while ensuring micro-mixing. Through optimized channel structure, local maximization of energy dissipation rate is achieved, allowing the reaction to proceed under optimal conditions, improving product yield and purity, while reducing pumping energy consumption.

[0020] Furthermore, this gap range ensures sufficient shearing at high linear velocities (up to 40 m / s) while avoiding mechanical interference or wear. Small gaps generate high shear rates, suitable for nano-dispersions; slightly larger gaps are suitable for high solids content systems; after gap optimization, micro-mixing time is significantly shortened, particle crushing efficiency is increased by more than 30%, equipment life is extended, and maintenance costs are reduced.

[0021] Furthermore, polyethylene has excellent corrosion resistance and elasticity, maintaining its seal under high-speed rotation to prevent the intrusion of reaction liquids that could lead to corrosion or malfunction; this improves the reliability of the equipment in highly corrosive environments, reduces downtime losses due to seal failure, and is suitable for harsh reaction conditions such as acids and alkalis.

[0022] Furthermore, bladed rotors are suitable for high flow rates, while toothed rotors enhance local shearing; electrochemical treatment creates a smooth surface, reducing material adhesion; this improves rotor wear resistance and cleanliness, avoiding cross-contamination, making them particularly suitable for pharmaceutical and food-grade production.

[0023] Furthermore, the stainless steel is corrosion-resistant, and the frosted surface enhances sealing, ensuring no leakage in a fully closed state; this extends the service life of the cover plate, guarantees the axial suction effect during solid-liquid dispersion, and improves operational safety.

[0024] Furthermore, the parameter range covers the conditions for most fast competitive reactions, and the high-shear design ensures that the reaction is completed within the kinetically matched time, broadening the application scenarios of the equipment. It can be used in fields such as pharmaceutical intermediates, dyes, and nanomaterial synthesis, improving the versatility of the process.

[0025] Furthermore, different materials are adapted to different corrosive and abrasive environments: ceramics and silicon carbide are resistant to high-temperature corrosion, while polymers are suitable for acid and alkali systems, which enhances the equipment's adaptability to extreme working conditions, reduces material costs, and extends its service life.

[0026] In summary, this invention addresses the pain points of traditional mixers through structural design optimization. The stator thickening combined with annular channels utilizes the principle of restricted impact flow to improve micromixing efficiency. The adjustable stator cover adapts to various scenarios, enhancing operational flexibility. Experiments show that its micromixing efficiency and depolymerization effect are superior to traditional equipment, while consuming less energy. Diverse materials and structures are suitable for different reactions, making it widely applicable. Furthermore, stability is improved through sealing and surface treatment, driving the upgrade of chemical equipment towards high efficiency, greenness, and multi-functionality.

[0027] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the following description of the relative embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of a fast-flow high-shear reactor with a liquid distributor according to the present invention; Figure 2 This is a schematic diagram of the stator cover plate; Figure 3 This is a schematic diagram of the motor and connecting rod; Figure 4 This is a schematic diagram of the reactor stator; Figure 5 This is a schematic diagram of the transmission rod and stator; Figure 6 This is a diagram illustrating the experimental process of Embodiment 1 of the present invention; Figure 7 This is a diagram illustrating the experimental process of Embodiment 2 of the present invention; Figure 8 A comparison chart of the performance of traditional high-shear micromixing and improved high-shear micromixing. Figure 9 This is a comparison chart of the depolymerization performance of traditional high-shear and improved high-shear methods.

[0030] The components are: 1. drive motor; 2. transmission rod; 3. threaded port; 4. stator cover plate; 5. stator; 6. annular channel; 7. annular gap of the channel; 8. feed inlet; 9. connecting rod; 10. rotor. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "one side," "one end," and "one side," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, in the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0034] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0035] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0036] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0037] The accompanying drawings illustrate various structural schematic diagrams according to embodiments disclosed in this invention. These drawings are not to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0038] This invention provides a high-shear mixer with enhanced solid-liquid dispersion and micro-mixing performance. When the stator cover is fully closed, it can be used for solid-liquid dispersion. The desired solid-liquid mixture is added to the container. Since most solids settle at the bottom, traditional stator designs, with their open tops, waste some axial suction. This invention seals the top of the stator, significantly strengthening the mixer's axial suction, allowing solids to be more evenly dispersed in the liquid. For reactions involving solids, the stator cover is adjusted to a semi-open state, enhancing radial flow without completely eliminating axial flow. Enhanced radial flow is more conducive to dispersing solid materials in the system, benefiting the reaction. This invention thickens the stator of traditional high-shear mixers and incorporates annular channels for conveying the liquid, acting as a liquid distributor. This allows the reaction to occur at the point of highest energy dissipation. Combined with the advantages of a confined impingement flow mixer, the collision of two liquid streams within the channels greatly improves micro-mixing efficiency, significantly promoting the yield and selectivity of various reactions. Featuring an adjustable stator cover, when fully open, this invention enhances micro-mixing between liquids, improving product yield and selectivity. When the stator cover is partially open, it significantly enhances radial flow while maintaining a certain axial flow capacity, further promoting solid-liquid dispersion and resulting in a more uniform reaction solution. When the stator cover is fully closed, the invention can also be used for solid-liquid dispersion; the enhanced axial flow after closing the stator cover allows for more uniform dispersion of solids within the liquid.

[0039] Please see Figure 1 This invention discloses a high-shear mixer with enhanced solid-liquid dispersion and micro-mixing performance, comprising a drive motor 1, a stirring shaft, a rotor 10, a stator 5 with a distributor, and a stator cover plate 4. The stator of a traditional high-shear mixer is improved by thickening the stator wall and adding openings between its walls for fluid passage. The distributor, achieved through 3D printing technology, distributes uniform channels within the stator 5 for transporting the reaction liquid. A cover plate 4 is added to the stator 5 so that materials can only be drawn in from the bottom for dispersion, making it particularly suitable for solid-liquid dispersion systems. This structural design also incorporates the working principle of a confined impinging flow reactor, achieving coupling between the high-shear mixer and the confined impinging flow reactor, significantly improving reaction efficiency.

[0040] Please see Figure 2 The reactor stator cover plate 4 is precision-machined from stainless steel with a frosted surface to ensure airtightness when the stator 5 is sealed. When this high-shear process is applied to solid-liquid dispersion, the fixing bolts completely seal the upper end of the stator 5, creating a stronger axial flow within the stator 5, which is beneficial for solid-liquid dispersion. During the reaction, removing the stator cover plate 4 allows for a stronger radial flow above the stator 5, further promoting micro-mixing. During the solid-liquid reaction, keeping the cover plate 4 partially open ensures axial circulation at the top of the stator 5 and also enhances axial circulation at the bottom. This facilitates uniform dispersion of solids in the fluid, providing favorable reaction conditions.

[0041] Please see Figure 3 This component is the power core and stabilizing mechanism. The power core is a high-power, high-speed, variable-speed control drive motor 1. The drive motor 1 adopts an air-cooled design and has a high-grade copper winding assembly inside, which has extremely high starting torque and stable speed accuracy. The connecting rod 9 is used to connect the stator 5. The high-strength stainless steel material has excellent fatigue resistance and torsional bending resistance characteristics, and can maintain the relative stability of the stator and rotor at ultra-high speeds.

[0042] Please see Figure 4 This component is stator 5, which differs from a regular stator in two ways: 1. The stator 5 has annular channels 6 in the stator wall, which allows the reaction solution to carry out chemical reactions directly in the high energy dissipation region, thus giving it higher conversion rate and selectivity.

[0043] 2. The stator 5 has been thickened, which lengthens the annular channel 6. During feeding, the extended annular channel 6 combines the advantages of a confined impinging flow reactor, converting the pressure energy of the fluid input into kinetic energy, enabling efficient mixing of the fluid in a very small space. This increases the micro-mixing efficiency.

[0044] The structural features of the annular channel 6 include one or a combination of circular, square, triangular, rhomboid, and corrugated shapes.

[0045] The channel gap 7 can take one of the following forms: uniform channel, gradually narrowing channel, or gradually widening channel. The size of the channel gap is 1-5 mm.

[0046] Please see Figure 5This component consists of rotor 10 and drive rod 2. Rotor 10 typically employs a bladed or toothed design and is machined from high-strength stainless steel. During operation, it can reach extremely high linear speeds (up to 40 m / s). Its surface undergoes a special electrochemical treatment during operation to ensure no material residue remains after processing. The connection between drive rod 2 and stator 5 experiences intense stress due to the extremely high rotational speed. Therefore, the connection is sealed with corrosion-resistant polyethylene material to prevent the reaction liquid from entering and causing corrosion, which could lead to breakage. Furthermore, the shear gap between rotor 10 and stator 5 is 1-3 mm, providing strong shear force for the reaction and resulting in excellent micro-mixing time.

[0047] Preferably, the reaction of the high-shear mixer for enhancing solid-liquid dispersion and micro-mixing performance of the present invention is one of the following: phosgenation, diazotization, rearrangement reaction, precipitation reaction; the reaction temperature is -30~80℃, and the reaction pressure is 0.1~5Mpa.

[0048] Preferably, the wall material of the high-shear mixer of the present invention, which enhances the solid-liquid dispersion and micro-mixing performance, is at least one of the following: stainless steel, nickel-based alloy, ceramic material, silicon carbide, or polymer.

[0049] By leveraging the synergistic effect of stator 9 and rotor 10, the problems of material agglomeration and localized overload inherent in traditional intermittent mixers are resolved, significantly improving mixing efficiency and product uniformity. This invention is particularly suitable for high-precision mixing processes such as nanomaterial dispersion and emulsion preparation, offering advantages such as low energy consumption and a wide applicable viscosity range.

[0050] This novel high-shear mixer, which separates two or more reactants into two parts, places one part into a container and pumps the other to the fluid inlet. The stator of this mixer features annular channels that act as a distributor, more evenly distributing the reactants between the stator and rotor, ensuring the reaction occurs at the point of highest energy dissipation. Furthermore, due to the thickened stator, this high-shear mixer, which enhances solid-liquid dispersion and micromixing performance, also incorporates the characteristics of a confined impingement flow reactor. The collision of the two reactants within the channels significantly improves micromixing efficiency, greatly promoting the yield and selectivity of various reactions.

[0051] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0052] Example 1: Comparison of micromixing performance between the improved reactor and the conventional reactor Non-Newtonian fluids, a large class of complex fluids whose rheological properties do not conform to Newton's law of viscosity, are widely found in modern industrial fields such as food, cosmetics, pharmaceuticals, chemicals, and biotechnology. Their rheological behaviors, including shear thinning, shear thickening, thixotropy, and yield stress, pose challenges to mixing. High-shear mixers, due to their extremely high local shear rates and energy densities, can effectively solve these problems. This improved reactor further enhances the efficiency of traditional high-shear mixers. The experimental scheme is as follows.

[0053] Experimental procedure: Open the stator cover. This is suitable for liquid-liquid reactions. The experiment uses the iodide-iodate reaction with added CMC (sodium carboxymethyl cellulose) to judge the micromixing performance of the reactor. The reaction formula is as follows: (instantaneous)(1) (veryfast)(2) (quasi-instantaneous)(3) Reaction (1) is a transient reaction, and its reaction rate far exceeds that of the second fast reaction (2). When the two solutions are perfectly mixed, H2BO3 - All H was consumed instantly through reaction (1). + While reaction (2) does not consume H+ + When the two solutions are in a non-ideal mixing state, H + Rapid dispersion cannot be achieved at the molecular scale, and H+ exists in local reaction regions. + Excessive concentration leads to H + After participating in the local reaction (1), it was still not completely consumed, so H +It will participate in reaction (2) to generate I2, which in turn promotes the transformation of the quasi-instantaneous equilibrium reaction (3) into I3. - Proceeding in the direction of I3. - I3 exhibits a strong characteristic absorption peak at a wavelength of 353 nm and can be detected using a visible light spectrophotometer. - The concentration.

[0054] Offset index X S The micro-mixing performance of a mixer is described as follows: (4) (5) (6) (7) The concentration of the compound is represented by [], and the subscript 0 indicates the initial state. V A , V B Let A and B represent the volumes of solutions A and B, respectively. Y This represents the ratio of the amount of hydrogen ions consumed in reaction (2) to the total amount of hydrogen ions consumed. Y ST For the mixing process in an infinitely slow state Y .therefore, X S =0 means the two fluids are completely mixed, while X S =1 represents complete separation of the two fluids. When 0 < X S When <1, the two fluids partially mix. X S The smaller the value, the higher the micromixing efficiency of the reactor.

[0055] Experimental Procedure: First, prepare buffer A and acid solution B, using analytical grade reagents. Deionized water was used for preparation. The experimental temperature was maintained at 20±1℃. Each experiment was repeated at least three times to ensure accuracy. Immediately after the reaction was completed, 5 mL of the reaction solution was taken, and the absorbance at 353 nm was measured using a visible light spectrophotometer. The micromixing efficiency was evaluated using the formula described above.

[0056] The concentrations of buffer A and acid are shown in Table 1: Table 1. Composition of the working fluid.

[0057] The experimental procedure is as follows Figure 6 As shown, the performance comparison between the traditional high-shear mixer and the improved high-shear mixer is presented. Figure 8 The graph shows a comparison of the micromixing performance of a traditional high-shear mixer and the improved high-shear mixer of this invention. The horizontal axis represents rotational speed (rpm), and the vertical axis represents the separation index XS. The experiment used the iodide-iodate reaction with added CMC as the evaluation system, and measured I3 at a wavelength of 353 nm. - The characteristic absorption peaks were analyzed, and the micromixing efficiency was calculated using the separation index XS formula (a smaller XS value indicates higher micromixing efficiency). The experimental temperature was maintained at 20±1℃, and each experiment was repeated three times to ensure accuracy. The figure shows that, under the same rotational speed, the separation index XS of the improved high-shear mixer is consistently lower than that of the traditional high-shear mixer, and the difference remains stable as the rotational speed increases. The overall micromixing efficiency is 20% higher than that of the traditional equipment. This demonstrates that the present invention, through structural optimizations such as the stator annular channel design and runoff enhancement under fully open stator cover conditions, effectively improves the micro-mixing capability of the liquid-liquid system, making the mixing characteristic time more closely match the chemical characteristic time of rapid competitive reactions, and reducing side reactions caused by local concentration differences.

[0058] Example 2: Comparison of depolymerization performance between the improved reactor and the conventional reactor Adding nanoparticles as additives to improve product quality is a common practice in industry. However, non-Newtonian fluids are prevalent in production and daily life, and their unique properties make the uniform mixing and dispersion of nanoparticles in products a challenge. High-shear mixers, due to their extremely high shear rates and energy dissipation rates, can rapidly break down and homogenize droplets, material clumps, and particle agglomerates.

[0059] Experimental Procedure: The stator cover was lowered for solid-liquid fragmentation. First, 20g of CMC was added to a mixing tank containing 10kg of deionized water and stirred continuously for 3 hours to obtain a 0.2wt% colorless and transparent CMC solution. Then, a certain mass of fumed SiO2 was placed into a jacketed beaker containing 350ml of CMC solution and pre-dispersed for 5 minutes using a stirrer (300rpm). After pre-dispersion, depolymerization was performed using both conventional high-shear and modified high-shear methods. Samples were continuously taken for analysis during the depolymerization process. Cooling water was used to control the temperature during both pre-dispersion and depolymerization processes, ensuring all experiments were completed at 20±1℃. The experimental procedure is as follows: Figure 7 As shown.

[0060] Please see Figure 9The figure compares the deagglomeration performance of traditional high-shear mixers and improved high-shear mixers. The horizontal axis represents time (in minutes), and the vertical axis represents the corresponding detection index (reflecting the degree of particle dispersion; the lower the value, the better the deagglomeration effect). The figure includes comparative curves under different speed conditions such as 3000 rpm and 4000 rpm. The experiment used a solid-liquid system composed of 0.2 wt% CMC solution and gaseous SiO2 as the research object. It was first pre-dispersed by stirring at 300 rpm for 5 minutes, and then deagglomerated using two different mixers. During the process, the temperature was controlled at 20±1℃ by cooling water, and samples were continuously taken for analysis. As can be seen from the figure, at each speed, the detection index corresponding to the improved high-shear mixer was lower than that of the traditional equipment, and the deagglomeration advantage became more obvious over time. The overall deagglomeration effect was 30% better than that of the traditional equipment. This confirms that the design of the present invention, such as the axial suction enhancement under the fully closed state of the stator cover and the optimization of the stator-rotor shear gap, can effectively solve the problem of solid settling, enhance the ability to break up solid agglomerates, and meet the requirements of efficient dispersion of solid materials in non-Newtonian fluids.

[0061] In summary, this invention provides a high-shear, flow-type mixer that enhances solid-liquid dispersion and micro-mixing performance. The annular channel and adjustable cover design shorten mixing time to the millisecond level, reduce the separation index by more than 20%, and significantly improve reaction selectivity. The axial suction enhancement mechanism solves the particle sedimentation problem, increasing deagglomeration efficiency by 30%. Energy consumption is reduced by 35%–50%, and material loss is reduced by 20%–30%, meeting green chemical engineering requirements. It is suitable for non-Newtonian fluids, high-solids-content systems, and various rapid reactions, offering multiple uses and reducing equipment investment. Optimized sealing and materials ensure long-term stable operation. This invention is a powerful tool for process intensification in the fields of fine chemicals, pharmaceuticals, and new materials.

[0062] The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made to the technical solution based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. A high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties, characterized in that, Includes a drive motor (1), which is connected to the rotor (10) via a transmission rod (2) and is used to drive the rotor (10) to rotate at high speed; A stator (5) is fitted outside the rotor (10), and a shear gap is formed between the stator (5) and the rotor (10) to generate a strong shearing effect; The upper part of the stator (5) is adjustablely provided with a stator cover plate (4), which is used to control the material suction method; The stator (5) has a thickened wall and an annular channel (6) is provided inside it. The annular channel (6) is used to transport the liquid material so that the liquid material is mixed in the high energy dissipation area between the stator (5) and the rotor (10).

2. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The stator cover (4) is configured to be fully open, half open, or fully closed: When fully open, it is suitable for liquid-liquid micro-mixing and enhances runoff; When partially open, it is suitable for solid-liquid reactions, accommodating both axial and radial flow; When fully closed, it is suitable for solid-liquid dispersion and enhances axial suction.

3. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The annular channel (6) is formed by 3D printing technology, and its cross-sectional shape is one or more combinations of circles, squares, triangles, rhombuses or corrugations.

4. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The gap (7) of the annular channel (6) is one of a uniform channel, a gradually narrowing channel or a gradually expanding channel, and the gap size is 1~5mm.

5. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The shear gap between the rotor (10) and the stator (5) is 1~3mm.

6. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The connection between the transmission rod (2) and the stator (5) is sealed with polyethylene material.

7. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The rotor (10) adopts a blade-type or tooth-type structure design and its surface is electrochemically treated.

8. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The stator cover plate (4) is made of stainless steel and has a frosted surface.

9. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The mixer is suitable for phosgenation, diazotization, rearrangement or precipitation reactions, with a reaction temperature of -30 to 80°C and a reaction pressure of 0.1 to 5 MPa.

10. The high-shear mixer with enhanced solid-liquid dispersion and micro-mixing properties according to claim 1, characterized in that, The stator (5) and rotor (10) are made of at least one of stainless steel, nickel-based alloy, ceramic material, silicon carbide or polymer.

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